WO2025003644A1

WO2025003644A1 - A hollow moulded fibre product transfer mechanism and associated method

Info

Publication number: WO2025003644A1
Application number: PCT/GB2024/051614
Authority: WO
Inventors: Adam Richard TURNER; Daniel George PROZESKY; Theo Richard ASHCROFT
Original assignee: Pulpex Limited
Priority date: 2023-06-29
Filing date: 2024-06-25
Publication date: 2025-01-02
Also published as: GB202309872D0; GB2631423A

Abstract

There is disclosed a method of inserting a hollow moulded fibre product into a mould part of a thermoforming mould, the method comprising: placing the hollow moulded fibre product in the mould part at a first angle relative to a split plane of the mould part; and subsequently causing the hollow moulded fibre product to move in the mould part to a second angle relative to the split plane, wherein the second angle is smaller than the first angle. Also disclosed is a hollow moulded fibre product transfer mechanism for inserting a hollow moulded fibre product into a mould part of a thermoforming mould.

Description

A HOLLOW MOULDED FIBRE PRODUCT TRANSFER MECHANISM AND

ASSOCIATED METHOD

TECHNICAL FIELD

The present invention relates to a hollow moulded fibre product transfer mechanism, a method of inserting a hollow moulded fibre product into a mould part of a thermoforming mould, and other systems and methods for manufacturing receptacles from a fibre suspension, such as a fibre suspension comprising paper pulp. The receptacles may be consumer packaging, such as bottles, jars or certain types of vases, useful for holding liquids, powders, other flowable materials, one or more solid objects, or a combination thereof.

BACKGROUND

It is desirable to reduce glass and plastics use in consumable items, particularly packaging. Non-necked receptacles, such as trays, bowls and other simple shapes, are commonly made from paper pulp. However, a more complex necked receptacle, like a bottle, jar or certain types of vase, is more difficult to engineer due to an internal narrowing of the receptacle between a main body portion of the receptacle and an opening of the receptacle.

At certain stages, particularly early stages, during formation of a hollow moulded fibre product, the hollow moulded fibre product may be relatively fragile. The hollow moulded fibre product may thus be easily damaged by impact, for example during handling of the hollow moulded fibre product.

SUMMARY

According to a first aspect of the present invention, there is provided a method of inserting a hollow moulded fibre product into a mould part of a thermoforming mould, the method comprising: placing the hollow moulded fibre product in the mould part at a first angle relative to a split plane of the mould part; and subsequently causing the hollow moulded fibre product to move in the mould part to a position orientated at a second angle relative to the split plane, wherein the second angle is smaller than the first angle.

At certain stages, particularly early stages, during formation of a hollow moulded fibre product, the hollow moulded fibre product may be relatively fragile. The hollow moulded fibre product may thus be easily damaged by impact, for example during handling of the hollow moulded fibre product. The disclosed method provides the advantage of helping to reduce the chance of damage to the hollow moulded fibre product as the hollow moulded fibre product is inserted into the mould part of the thermoforming mould.

A thermoforming mould comprises a plurality of mould parts each defining a respective cavity for receiving part of the hollow moulded fibre product. During moulding by the thermoforming mould, the plurality of mould parts is held together so that each mould part abuts at least one other mould part along a split plane. When held together, the mould parts define a mould cavity in which the hollow moulded fibre product is moulded by the thermoforming mould. During initial moulding of a hollow moulded fibre product, stray fibres extending from an outer surface of the hollow moulded fibre product can become trapped between abutting mould parts of a subsequent thermoforming mould, so that they particularly accumulate around the rim of each mould part. The mould parts of a thermoforming mould are held, or clamped, shut by the application of a relatively large pressure, such that the trapped fibres can damage contacting surfaces of the mould parts. By inserting a hollow moulded fibre product into a mould part using the disclosed method, there is less contact between the hollow moulded fibre product and the thermoforming mould so that the chance of fibres accumulating on a rim of the mould part is lessened compared with sliding the hollow moulded fibre product into the mould part at a single angle.

Optionally, placing the hollow moulded fibre product in the mould part comprises placing part of the hollow moulded fibre product in a cavity of the mould part with the product at the first angle. Optionally, the split plane extends across an opening of a cavity of the mould part, and the hollow moulded fibre product passes through the opening during the placing of the hollow moulded fibre product in the mould part at the first angle relative to the split plane.

Optionally, a central longitudinal axis of the hollow moulded fibre product lies on the split plane during subsequent use of the thermoforming mould to thermoform the product.

Optionally, the placing the hollow moulded fibre product in the mould part at the first angle relative to the split plane of the mould part comprises inserting a base end portion of the hollow moulded fibre product into the mould part, and the subsequently causing the hollow moulded fibre product to move in the mould part to a position orientated at the second angle relative to the split plane comprises causing an upper end portion of the hollow moulded fibre product to enter the mould part, the upper end portion being at an opposite end of the hollow moulded fibre product to the base end portion. This may reduce a chance that a leading edge of the base end portion of the hollow moulded fibre product catches on a rim of the mould part during the placing of the hollow moulded fibre product in the mould part at the first angle. In turn, this may further reduce a chance of damage to the hollow moulded fibre product during insertion of the hollow moulded fibre product into the mould part of the thermoforming mould.

Optionally, the hollow moulded fibre product is a necked hollow moulded fibre product, such as a bottle, and the upper end portion is a necked portion of the hollow moulded fibre product. Typically, a necked portion of a necked hollow moulded fibre product has a smaller cross-sectional area than a base end portion. Accordingly, vertical insertion of the necked hollow moulded fibre product into a mould part of a thermoforming mould is not possible due to a base end portion of the necked hollow moulded fibre product being wider than a neck and shoulder portion of the mould part so that the base end portion could not fit through an opening at the neck portion of the mould part. Due to its smaller cross-sectional area, the necked portion may be more prone to damage during handling of the necked hollow moulded fibre product than the base end portion. Accordingly, placing the base end portion into the mould part first may help to reduce the chance of damage to the necked portion compared with placing the necked portion into the mould part first because a wider range of motion is available if the base end portion is inserted first.

Optionally, the subsequently causing the hollow moulded fibre product to move to the position orientated at the second angle relative to the split plane comprises applying a force to the hollow moulded fibre product to move the hollow moulded fibre product towards the second angle. This may provide more control of movement of the hollow moulded fibre product to the position orientated at the second angle, compared with the hollow moulded fibre product moving to the position orientated at the second angle solely under gravity. This may help to ensure the hollow moulded fibre product is correctly positioned in the thermoforming mould.

Optionally, applying the force to the hollow moulded fibre product causes the hollow moulded fibre product to tip, rotate or roll to the position orientated at the second angle. This may further help to lessen the accumulation of fibres at a rim of the mould part.

Optionally, the first angle is at least 5 degrees from the split plane of the mould part. This may help to lessen the accumulation of fibres at a rim of the mould part compared with smaller angles.

Optionally, the first angle is at least 8 degrees from the split plane of the mould part. This may help to further lessen the accumulation of fibres at a rim of the mould part compared with smaller angles. This may be particularly beneficial in examples in which a base portion of the mould part defines a raised portion for forming a punt in a base end portion of the hollow moulded fibre product, and the base end portion of the hollow moulded fibre product is placed into the mould part at the first angle. Optionally, the first angle is at least 15 degrees from the split plane of the mould part. An angle of at least 15 degrees may be particularly helpful to ensure that the base end portion of hollow moulded fibre product does not catch on the raised portion.

Optionally, the first angle is no greater than 20 degrees from the split plane of the mould part. This may permit insertion of the hollow moulded fibre product into the mould part between a plurality of mould parts of the thermoforming mould in a space-efficient manner. That is, the plurality of mould parts may be separated by a distance less than a height of the hollow moulded fibre product whilst still permitting the hollow moulded fibre product to be inserted into the mould part.

Optionally, the second angle is no greater than 3 degrees from the split plane of the mould part. This may help to lessen a chance of the hollow moulded fibre product catching on, and potentially being damaged by, a rim of the mould part as the thermoforming mould is closed for thermoforming the hollow moulded fibre product.

Optionally, the second angle is substantially zero degrees from the split plane of the mould part. That is, at the position orientated at the second angle, the hollow moulded fibre product may fit snugly against the mould part of the thermoforming mould. This may help to further lessen a chance of the hollow moulded fibre product catching on, and potentially being damaged by, a rim of the mould part as the thermoforming mould is closed for thermoforming the hollow moulded fibre product.

Optionally, the second angle corresponds to a moulding angle of the hollow moulded fibre product relative to the mould part, the moulding angle being an angle of the hollow moulded fibre product relative to the mould part at which the hollow moulded fibre product is moulded by the thermoforming mould. This may help to lessen accumulation of stray fibres at a rim of the mould part of the thermoforming mould as the thermoforming mould is closed for thermoforming the hollow moulded fibre product.

Optionally, a central longitudinal axis of the hollow moulded fibre product is aligned with the split plane of the mould part when the hollow moulded fibre product is orientated at the second angle. Optionally, the hollow moulded fibre product is a necked hollow moulded fibre product, such as a bottle, and the central longitudinal axis is a central axis of a necked portion of the necked hollow moulded fibre product. This may help to ensure that the hollow moulded fibre product is in a correct position for use of the thermoforming mould, which may help to lessen accumulation of stray fibres at a rim of the mould part of the thermoforming mould as the thermoforming mould is closed for thermoforming the hollow moulded fibre product.

According to a second aspect of the present invention, there is provided a hollow moulded fibre product transfer mechanism for inserting a hollow moulded fibre product into a mould part of a thermoforming mould, the hollow moulded fibre product transfer mechanism configured to: partially insert the hollow moulded fibre product into the mould part at a first angle relative to a split plane of the mould part, and subsequently cause the hollow moulded fibre product to move in the mould part to a position orientated at a second angle relative to the split plane to further insert the hollow moulded fibre product into the mould part, wherein the second angle is smaller than the first angle.

At certain stages, particularly early stages, during formation of a hollow moulded fibre product, the hollow moulded fibre product may be relatively fragile. The hollow moulded fibre product may thus be easily damaged by impact, for example during handling of the hollow moulded fibre product. The hollow moulded fibre product transfer mechanism provides the advantage of helping to reduce the chance of damage to the hollow moulded fibre product as the hollow moulded fibre product is inserted into the mould part.

During initial moulding of a hollow moulded fibre product, stray fibres extending from an outer surface of the hollow moulded fibre product can become trapped between the mould parts of a subsequent thermoforming mould. The thermoforming mould holds, or clamps, shut with a relatively large pressure, compared with moulds used for forming non-hollow moulded fibre products, such that the trapped fibres can damage contacting surfaces of the thermoforming mould. By inserting a hollow moulded fibre product into a mould part using the hollow moulded fibre product transfer mechanism, the chance of fibres accumulating on a rim of the mould part is lessened compared with sliding the hollow moulded fibre product into the mould part at a single angle.

In some examples, the hollow moulded fibre product transfer mechanism is a necked hollow moulded fibre product transfer mechanism, for example, a moulded fibre bottle transfer mechanism.

Optionally, the hollow moulded fibre product transfer mechanism is configured to partially insert a base end portion of the hollow moulded fibre product into the mould part such that the hollow moulded fibre product is at the first angle, and subsequently cause the hollow moulded fibre product to move in the mould part to a position orientated at the second angle relative to the split plane by partially inserting an upper end portion of the hollow moulded fibre product into the mould part, the upper end portion being at an opposite end of the hollow moulded fibre product to the base end portion. This may reduce a chance that a leading edge of the base end portion of the hollow moulded fibre product catches on a rim of the mould part during the inserting of the base end portion. In turn, this may further reduce a chance of damage to the hollow moulded fibre product during inserting of the hollow moulded fibre product into the mould part.

Optionally, the hollow moulded fibre product transfer mechanism is configured to apply a force to the hollow moulded fibre product to move the hollow moulded fibre product towards the position orientated at the second angle. This may provide more control of movement of the hollow moulded fibre product to the position orientated at the second angle, compared with the hollow moulded fibre product moving to the position orientated at the second angle solely under gravity. This may help to ensure the hollow moulded fibre product is correctly positioned in the thermoforming mould.

Optionally, applying the force to the hollow moulded fibre product comprises the hollow moulded fibre transfer mechanism tipping, rotating or rolling the hollow moulded fibre product towards, or to, the position orientated at the second angle. This may further help to lessen the accumulation of fibres at a rim of the thermoforming mould. Optionally, the transfer mechanism is configured to apply a pushing force to the hollow moulded fibre product to cause the hollow moulded fibre product to move to the position orientated at the second angle, for example by applying a positive air pressure to the hollow moulded fibre product. This may provide more control of movement of the hollow moulded fibre product to the position orientated at the second angle, compared with the hollow moulded fibre product being released by the suction generator at the first angle and the hollow moulded fibre product moving to the position orientated at the second angle solely under gravity. This may provide a simple way of applying a force to the hollow moulded fibre product to move the hollow moulded fibre product towards the position orientated at the second angle.

Optionally, the transfer mechanism comprises a contact surface for contacting a surface of the hollow moulded fibre product; a suction generator configured to apply a suction force to the surface of the hollow moulded fibre product to retain the hollow moulded fibre product against the contact surface; and an actuation system configured to move the contact surface, with the hollow moulded fibre product retained against the contact surface by the suction generator, relative to the mould part and partially insert the hollow moulded fibre product into the mould part at the first angle. This may allow rapid transfer of the hollow moulded fibre product to the mould part with a reduced chance of damage being caused during the transfer and insertion into the mould part.

Optionally, the contact surface substantially corresponds in shape to an outer wall of the mould part. This may further help to reduce a chance of damage being caused to the hollow moulded fibre product, by spreading force applied to the hollow moulded fibre product across the contact surface.

Optionally, the contact surface comprises a plurality of apertures through which air is drawn by the suction generator to apply the suction force to the hollow moulded fibre product. This may help to apply a relatively even suction force to the hollow moulded fibre product during use of the transfer mechanism, which may further help to reduce a chance of damage being caused to the hollow moulded fibre product. Optionally, the suction generator is configured to release the surface of the hollow moulded fibre product from the contact surface when the actuation system has partially inserted the hollow moulded fibre product into the thermoforming mould. This may allow the required movement of the contact surface by the actuation system to be simplified compared with the contact surface moving the hollow moulded fibre product to the position orientated at the second angle.

Optionally, the suction generator is configured to release the surface of the hollow moulded fibre product from the contact surface when the actuation system has partially inserted the hollow moulded fibre product into the thermoforming mould at the first angle. This may help to ensure that the hollow moulded fibre product is correctly positioned at the first angle.

Optionally, the suction generator is configured to release the surface of the hollow moulded fibre product from the contact surface when the actuation system has partially inserted the hollow moulded fibre product into the thermoforming mould, before the hollow moulded fibre product reaches the first angle. This may reduce an amount of actuation required by the actuation system, which may help to reduce a time taken by the actuation system to partially insert the hollow moulded fibre product into the mould part at a first angle relative to a split plane of the mould part.

Optionally, the transfer mechanism is configured to apply a pushing force to a surface of the hollow moulded fibre product in a direction away from the contact surface to release the surface of the hollow moulded fibre product from the contact surface. This may help to ensure that the hollow moulded fibre product disengages from the contact surface and is able to move to the position orientated at the second angle.

Optionally, the actuation system is configured to subsequently move the contact surface, with the hollow moulded fibre product retained against the contact surface by the suction generator, to move the hollow moulded fibre product towards the position orientated at the second angle. This may provide more control of movement of the hollow moulded fibre product to the position orientated at the second angle, compared with the hollow moulded fibre product being released by the suction generator at the first angle and the hollow moulded fibre product moving to the position orientated at the second angle solely under gravity. This may help to ensure the hollow moulded fibre product is correctly positioned in the thermoforming mould.

Optionally, the suction generator is configured to release the surface of the hollow moulded fibre product from the contact surface when the actuation system has moved the hollow moulded fibre product to the position orientated at the second angle. This may provide yet more control of movement of the hollow moulded fibre product to the position orientated at the second angle.

Optionally, the hollow moulded fibre product transfer mechanism comprises a second actuation system configured to move the hollow moulded fibre product towards the position orientated at the second angle. This may provide more control of movement of the hollow moulded fibre product to the second angle, compared with the hollow moulded fibre product being released by the suction generator at the first angle and the hollow moulded fibre product moving to the position orientated at the second angle solely under gravity.

Optionally, the second actuation system comprises a second suction generator configured to draw air through the mould part of the thermoforming mould to draw the hollow moulded fibre product towards the mould part. This may then draw the hollow moulded fibre product towards, or to, the position orientated at the second angle without physically gripping, and thus potentially damaging, the product.

Optionally, the hollow moulded fibre product transfer mechanism is configured, before partially inserting the hollow moulded fibre product into the mould part at the first angle relative to the split plane of the mould part, to: remove the hollow moulded fibre product from a first mould, the first mould being for moulding the hollow moulded fibre product before moulding of the hollow moulded fibre product by the thermoforming mould; and rotate the hollow moulded fibre product to the first angle. This may provide an efficient system for moving the hollow moulded fibre product between moulds, which may help to lessen a chance of damage being caused to the hollow moulded fibre product during forming of the hollow moulded fibre product.

According to a third aspect of the present invention, there is provided a thermoforming system for processing a hollow moulded fibre product, the thermoforming system comprising a hollow moulded fibre product transfer mechanism of the second aspect, and a thermoforming mould comprising a plurality of mould parts, the transfer mechanism configured to: partially insert the hollow moulded fibre product into one of the mould parts of the thermoforming mould at the first angle relative to a split plane of the mould part, and subsequently cause the hollow moulded fibre product to move to the position orientated at the second angle relative to the split plane to further insert the hollow moulded fibre product into the mould part.

Optionally, the thermoforming mould is configured to hold the plurality of mould parts closed with a force that is greater than or equal to a force exerted by an expandable member, such as a bladder, on the thermoforming mould in use, the expandable member being inserted within the hollow moulded fibre product during use of the thermoforming mould and urged against internal surfaces of the hollow moulded fibre product when expanded. This may help to overcome pressure exerted against the internal surfaces of the thermoforming mould by the expandable member inserted within the hollow moulded fibre product during use of the thermoforming mould.

Optionally, the thermoforming mould is configured to hold the plurality of mould parts closed with a pressure of at least 15 bar, or at least 20 bar.

According to a fourth aspect of the present invention, there is provided a method of operating a thermoforming system of the third aspect, the method comprising: causing the hollow moulded fibre product transfer mechanism to place the hollow moulded fibre product in the mould part at the first angle relative to the split plane of the mould part; and subsequently causing the hollow moulded fibre product to move to the position orientated at the second angle relative to the split plane. According to a fifth aspect of the present invention, there is provided a control system configured to cause a hollow moulded fibre product transfer mechanism to perform a method of the first aspect, or to cause a thermoforming system to perform a method of the fourth aspect.

According to a sixth aspect of the present invention, there is provided a non- transitory storage medium storing machine-readable instructions that, when executed by a processor of a control system of a transfer mechanism, cause the transfer mechanism to perform a method of the first aspect, or a method of the fourth aspect.

According to a seventh aspect of the present invention, there is provided a receptacle manufacturing line comprising a thermoforming system of the third aspect for processing the hollow moulded fibre product, and apparatus for performing at least one additional process on the hollow moulded fibre product to provide the receptacle.

The apparatus may comprise an interior coater and the at least one additional process may comprise the interior coater coating at least a portion of an interior of the product to produce an internally coated product. The apparatus may comprise a closurepart applicator and the at least one additional process may comprise the closure-part applicator applying a closure part to the product or the internally coated product to produce a closable or closed product. The apparatus may comprise an exterior coater and the at least one additional process may comprise the exterior coater coating at least a portion of an exterior of the product or the internally coated product or the closable or closed product to produce an externally coated product. The apparatus may comprise a decorator and the at least one additional process may comprise the decorator decorating the product or the internally coated product or the closable or closed product or the externally coated product to produce a decorated product. The apparatus may comprise a dryer and the at least one additional process may comprise the dryer drying the product or the internally coated product or the closable or closed product or the externally coated product or the decorated product to produce a dried product. The apparatus may comprise an evaluator and the at least one additional process may comprise the evaluator evaluating the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, or the dried product to produce an evaluated product. In some examples, the receptacle is the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, the dried product, or the evaluated product.

In some examples, the receptacle is a necked receptacle, such as a bottle, jar or a type of vase, and the receptacle manufacturing line is a necked-receptacle manufacturing line. In some examples, the receptacle is a bottle.

According to an eighth aspect of the present invention, there is provided a method of manufacturing a receptacle, the method comprising performing the method of the first aspect to provide a hollow moulded fibre product, thermoforming the hollow moulded fibre product in the thermoforming mould to provide a thermoformed hollow moulded fibre product, and then performing at least one additional process on the thermoformed hollow moulded fibre product to provide the receptacle.

The at least one additional process may comprise coating at least a portion of an interior of the product to produce an internally coated product. The at least one additional process may comprise applying a closure part to the product or the internally coated product to produce a closable or closed product. The at least one additional process may comprise coating at least a portion of an exterior of the product or the internally coated product or the closable or closed product to produce an externally coated product. The at least one additional process may comprise decorating the product or the internally coated product or the closable or closed product or the externally coated product to produce a decorated product. The at least one additional process may comprise drying the product or the internally coated product or the closable or closed product or the externally coated product or the decorated product to produce a dried product. The at least one additional process may comprise evaluating the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, or the dried product to produce an evaluated product. In some examples, the receptacle is the product, the internally coated product, the closable or closed product, the externally coated product, the decorated product, the dried product, or the evaluated product. In some examples, the receptacle is a necked receptacle, such as a bottle, jar or a type of vase. In some examples, the receptacle is a bottle.

According to a ninth aspect of the present invention, there is provided a method of providing a content-containing receptacle, the method comprising providing a receptacle obtained by a method of the eighth aspect and providing contents in the receptacle to provide the content-containing receptacle.

In some examples, the providing contents in the receptacle comprises putting the contents into the receptacle. In contrast, in some examples, the providing the contentcontaining receptacle comprises providing the receptacle with the contents already present in the receptacle, thereby providing the contents in the receptacle.

The contents may be in the form of, for example, a liquid, a powder, other flowable materials, one or more solid objects, or a combination thereof. For example, the contents may be a foodstuff such as a condiment, a beverage such as an alcoholic beverage, a household care product such as a detergent or other cleaning product, a personal care product such as a hair care product or a personal cleansing product or a healthcare product or a pharmaceutical product or a cosmetics product, a fragrance product such as a perfume, a vehicle product such as motor oil, or an industrial product. Other suitable contents will be apparent to the skilled reader in view of the content of this application and their common general knowledge.

In some examples, the receptacle is a necked receptacle, such as a bottle, a jar or a type of vase. In some examples, the receptacle is a bottle.

In some examples, the method comprises closing an opening of the receptacle after the providing contents in the receptacle, and/or applying a label or indicia to the receptacle.

In some examples, the closing comprises applying a closure (such as a lid or a cap or a heat seal) to the receptacle to close the opening. In some examples, the closing comprises applying a heat seal to the receptacle and (e.g., thereafter) applying a lid or a cap to the receptacle.

In some examples, the applying the label or indicia to the receptacle occurs after the providing the contents in the receptacle (that is, the label or indicia is applied to the content-containing receptacle). In other examples, the applying the label or indicia to the receptacle occurs before or during the providing the contents in the receptacle.

In some examples, the applying occurs before the closing. In some examples, the applying occurs after the closing. In some examples, the applying occurs during the closing.

According to a tenth aspect of the present invention, there is provided use of a receptacle obtained by a method of the eight aspect to contain contents. The use could be, for example, by a person (such as a natural person or a company) who puts the contents into the receptacle, or by a person who transports the contents, or by a person who wishes to dispose of (e.g., to a consumer or end user), offer to dispose of (e.g., to a consumer or end user), import, or keep the contents whether for disposal or otherwise.

The contents may, for example, be in the form of any of those discussed above.

It will be appreciated that optional features of aspects of the present invention may be equally applied to other aspects of the present invention, where appropriate.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a schematic view of an example receptacle manufacturing line for performing a method of manufacturing receptacles from paper pulp;

Figure 2 is a schematic, partially cross-sectional side view of a thermoforming system, according to an example;

Figure 3 is a perspective view of a contact portion of an example transfer mechanism of the thermoforming system of Figure 2;

Figures 4a-4e are schematic, partially cross-sectional side views of the thermoforming system of Figure 2 in various use positions;

Figure 5 shows a method of operating a thermoforming system, according to an example;

Figure 6 shows a method inserting a hollow moulded fibre product into a mould part of a thermoforming mould, according to an example;

Figure 7 shows a non-transitory computer-readable storage medium according to an example;

Figure 8 shows a schematic cross-sectional view of a receptacle containing contents, according to an example; and

Figure 9 shows a method of providing a content-containing receptacle.

DETAILED DESCRIPTION

The following description presents exemplary embodiments and, together with the drawings, serves to explain principles of embodiments of the invention.

Figure 1 shows a receptacle manufacturing line 1 for performing a method of manufacturing receptacles, in this case necked receptacles, and more specifically in this case in the form of bottles, from paper pulp (i.e., which can form the basis of an example fibre suspension). By “necked receptacle” it is meant that the receptacle has an internal narrowing, or “neck”, between a main body portion, in which most of or all the contents of the receptacle are stored in use, and an opening through which the contents can enter or leave the receptacle in use. The internal width of the receptacle at the neck may be the same as or different to the internal width of the opening. However, the internal width of the neck is smaller than that of the main body portion, so that a shoulder is defined by and between the neck and the main body portion. This shoulder complicates manufacture of the receptacle, since it interferes with subsequent removal (and, in some cases, insertion) of whatever mould tool is inserted into the receptacle to form the internal shape of the receptacle. Examples of necked receptacles are bottles, jars, and certain types of vases. The process is merely exemplary and is provided to give context to examples of the present invention. It will be appreciated that, in other examples, the receptacle manufacturing line could be for making non-necked receptacles (i.e., receptacles without such a neck), such as bowls or trays.

Broadly speaking, the exemplary process comprises providing a fibre suspension, introducing the fibre suspension into a mould cavity of a porous first mould and expelling a liquid (such as water) from the fibre suspension to produce a hollow moulded fibre product (which may be called a wet precursor or embryo) in the mould cavity, further moulding the hollow moulded fibre product to produce a hollow further-moulded fibre product, drying and then internally-coating the hollow further-moulded fibre product to produce an internally coated product, drying the internally coated product to produce a dried product, applying a closure part to the dried product to produce a closable or closed product, externally-coating and/or decorating the closable or closed product to produce an externally coated and/or decorated product, and then drying the externally coated or decorated product to produce another dried product. As will be apparent at least from the following description, modifications may be made to the exemplary process to provide variants thereof in which other examples of the present invention may be embodied. For example, in some cases, either the internal coating or the external coating and/or decorating may be omitted. Moreover, in the present case and as indicated by the stars labelled Ins. 1 to Ins. 5 in Figure 1, the process comprises inspecting or evaluating the hollow further-moulded fibre product, the internally coated product, the closable or closed product, the externally coated or decorated product, and the dried product to produce respective evaluated products. In some examples, the receptacle is the hollow moulded fibre product, the hollow further-moulded fibre product, the internally coated product, the closable or closed product, the externally coated or decorated product, one of the dried products, or one of the respective evaluated products.

In this example, providing the fibre suspension comprises preparing the fibre suspension from ingredients thereof. More specifically, the preparing comprises providing pulp fibres, such as paper pulp fibres, and mixing the pulp fibres with a liquid to provide hydrated pulp fibres. In this example, the pulp fibres are provided in sheet form from a supplier and the liquid comprises water and one or more additives. In this example, the liquid is mixed with the pulp fibres to provide hydrated pulp fibres having a solid fibres content of lwt% to 5wt% (by dry mass of fibres). In examples, the one or more additives includes a sizing agent, such as alkylketene dimer (AKD). The hydrated pulp fibres typically comprise AKD in an amount of 0.4wt% with respect to the total dry mass of the solid fibres in the hydrated pulp fibres. In some examples, one or more additives are present in the liquid at the point of mixing the pulp fibres with the liquid. In some examples, one or more additives are included in the hydrated pulp fibres after mixing the pulp fibres with the liquid (for example, the pulp fibres are hydrated for a period of time, such as from 2 to 16 hours, and then one or more additives are supplied to the hydrated pulp fibres). The hydrated pulp fibres are passed between plates of a valley beater 11 or refiner that are in motion relative to each other. This fibrillates some, or all, of the fibres, meaning that cell walls of those fibres are caused to become partially delaminated so that wetted surfaces of those fibres comprise protruding hairs or fibrillations. These fibrillations will help to increase a strength of bonds between the fibres in the dried end product. In other examples, the valley beater 11 or refiner may be omitted.

The resultant processed pulp is stored in a vat 12 in a relatively concentrated form (for example, a solid fibres content of lwt% to 5wt%) to reduce a required storage space. At an appropriate time, the processed pulp is transferred to a mixing station 13 at which the processed pulp is diluted in further water and, optionally, mixed with one or more additives (as well as, or in place of, the one or more additives provided with the hydrated pulp fibres) to provide the fibre suspension ready for moulding. In this example, the solid fibres account for 0.7wt% of the resultant fibre suspension (by dry weight of fibres), but in other examples the proportion of solid fibres in the fibre suspension may be different, such as another value in the range of 0.5wt% to 5wt%, or 0.1 wt% to lwt%, of the fibre suspension (by dry weight of fibres). In some examples, the one or more additives mixed with the processed pulp and water includes a dewatering agent, such as modified and/or unmodified polyethylene imine (PEI), for example modified PEI sold under the trade name Polymin® SK. In some examples, the one or more additives are mixed with the water, and the water and one or more additives subsequently mixed with the processed pulp; in other examples, the processed pulp and water are mixed, and the one or more additives subsequently mixed with the processed pulp and water. The fibre suspension typically comprises Polymin® SK in an amount of 0.3wt% with respect to the total dry mass of the solid fibres. Mixing of the fibre suspension at the mixing station 13 helps to homogenise the fibre suspension. In other examples, the processed pulp or the fibre suspension may be provided in other ways, such as being supplied ready-made.

Downstream of the vat 12 and the mixing station 13 is a first moulding station that comprises a porous first mould 15. In this example, the porous first mould 15 comprises two half-moulds 14 that are movable towards and away from each other, in this case using a hydraulic ram. In this example, each of the half-moulds 14 is a monolithic or unitary tool formed by additive manufacturing (for example, 3D-printing) that defines a mould profile, and, when the half-moulds 14 are brought into contact with each other, their respective mould profiles cooperate to define the mould cavity in which the hollow moulded fibre product is to be formed. Each half-mould 14 itself defines a smaller moulding cavity and, when brought into cooperation with a second half-mould 14, the smaller moulding cavities combine to provide the overall mould cavity. The two halfmoulds 14 may themselves be considered “parts”, “splits” or “moulds” and the overall porous first mould 15 may be considered a “split-mould” or, again, a “mould”. In other examples, the porous first mould 15 may comprise more than two splits 14, such as three, four or six splits, that cooperate to define the moulding cavity.

In Figure 1, the fibre suspension (also known as slurry) is top-filled into the porous first mould 15, in contrast to moulding processes that dip a mould in slurry. The fibre suspension is drawn under vacuum via a line 16 and into the porous first mould 15, with excess suspending liquid being drawn through the porous first mould 15 under vacuum via a line 18 into a tank 17. Shot mass may be controlled by measuring (for example, weighing) the amount of liquid drawn into the tank 17. A weight scale platform supporting the tank 17 is visible in Figure 1. Once a required amount (for example, a predetermined volume, such as 10 litres, or a predetermined mass, such as 10 kilograms) of liquid has been collected in the tank 17, suction of the suspending liquid through the porous first mould 15 is stopped and the first mould 15 is opened to ambient air. In this example, the suspending liquid drawn with the fibre suspension in line 16 is water, or predominantly water (as additives may also be present). The liquid drawn under vacuum via the line 18 and into the tank 17 is substantially free of fibres, since these are left behind against the walls of the porous first mould 15 to form the hollow moulded fibre product.

In one example, in order to remove further suspending liquid (for example, water) from the hollow moulded fibre product, and form or consolidate the three-dimensional shape of the product, high pressure fluid (such as compressed air) is introduced into the first mould 15 to compress the fibre suspension against the cavity wall of the first mould 15. This process strengthens the product so that it can be handled, and displaces water from in between the fibres, thereby increasing the efficiency of a subsequent drying process. The fluid is regulated using a hydraulic pump 20. The pump 20 has a cylinder that displaces the fluid in a line 21 into the first mould 15. In an alternative example, an impermeable inflation element in the form of a collapsible bladder is inserted into the first mould 15 and expanded, by introduction of a fluid into the bladder from the line 21, to act as an internal high-pressure core structure for the first mould 15. In such an alternative, the fluid within the line 21 is preferably non-compressible, such as water or oil, although in other examples it could be a compressible fluid, such as air. Water has the advantage over other non-compressible liquids that any leaking or bursting of the bladder will not introduce a new substance to the system (since the suspending liquid is already water, or predominantly water).

Demoulding occurs when the first mould 15 opens for removal of the self- supporting hollow moulded fibre product 22. Mould cleaning 23 is preferably performed subsequently, to remove any remaining small fibres and/or other debris and maintain a porosity of the porous first mould 15. In this example, a radially firing high-pressure jet is inserted into the mould cavity while the first mould 15 is open. This dislodges debris from the wall of the mould cavity. Alternatively, or in addition, water from the tank 17 is pressurised through the back of the porous first mould 15 to dislodge entrapped fibres and/or other debris. Water is drained for recycling back to an upstream part of the system. It is noteworthy that cleaning is important for conditioning the first mould 15 for re-use. The first mould 15 may appear visibly clean after removal of the receptacle, but its performance could be compromised without cleaning.

According to Figure 1, the hollow moulded fibre product 22 is subsequently transported to a second moulding station where, in a, for example, aluminium, mould 25, pressure and heat are applied for thermoforming a desired neck and surface finish, optionally including embossed and/or debossed surface features. After two halves of the mould 25 have closed around the product 22, a pressuriser is engaged. For example, a bladder 26 (for example, a thermoforming bladder 26) is inserted into the product 22. The bladder 26 is inflated with a pressurised fluid supplied via a line 27 by a pump 28. The pressurised fluid is preferably a non-compressible fluid such as water or oil, although in other examples it could be a compressible fluid such as air. In other examples, during supply, the pressurised fluid is heated with, for example, a heater or, alternatively, is cooled with, for example, a heat exchanger. An external mould block 24 of the mould 25, and/or the mould 25 itself, is also, or alternatively, heated in some examples. After thermoforming, a state of the product 22, which may now be considered a hollow further- moulded fibre product, is considerably more rigid, with more compressed side walls, as compared with the state of the product 22 at demoulding from the first mould 15.

A drying stage 30 (for example, a microwave drying process or other drying process) is performed on the product 22 downstream of the thermoforming, as shown, to provide a dried product. In one example, the drying stage 30 is performed before thermoforming to provide a dried product. However, moulding in the mould 25 requires some water content to assist with bonding during the compression process. The drying may be performed using a dryer, such as a machine that acts to cause drying of the product or simply a shelf or other support on which the product 22 rests while drying. The product 22 is then subjected to an internal-coating stage during which, in this example, an interior coater in the form of a spray lance 31 is inserted into the product 22 and applies one or more surface coatings to internal walls of the product 22 to produce an internally coated product. In another example, the product 22 is instead filled with and subsequently drained of a liquid that coats the internal walls of the product 22. In practice, such coatings provide a protective layer to prevent egress of contents into the bottle wall, which may permeate and/or weaken it. Coatings will be selected dependent on the intended contents of finished receptacle, for example, a beverage, foodstuff, detergent, lubricant, pharmaceutical product, etc. In this example, the internally coated product 22 is then subjected to a curing or drying process 32, which can be configured or optimised dependent on the internal coating, for example, drying for twenty-four hours at ambient conditions or by a flash drying method. The drying again may be performed using a dryer, such as a machine that acts to cause drying of the product or simply a shelf or other support on which the product 22 rests while drying. Following the drying, the coated product 22 is considered another dried product.

A closure or mouth forming process is then performed on the product 22 by a closure-part applicator to produce a closable or closed product. For example, as shown in Figure 1, a neck fitment 33 is affixed to the dried product. This results in the product being closable subsequently by positioning of a cap, lid or other closure relative to the neck fitment. An exterior coating and/or decoration is then applied to the product 22 by an exterior coater and/or a decorator, respectively, as shown in the further stage 34, to produce an externally coated and/or decorated product. In one example, the product 22 is dipped into a liquid to coat its outer surface, as shown in Figure 1. In another example, the outer surface receives the external coating in a different manner. The coating and/or decoration may cover all or only part of an external surface of the product. The product 22 is then allowed to dry in warm air to produce another dried product. In other examples, the drying may be performed using a dryer such as one of those discussed above.

The product 22 may therefore be fully formed, considered the end “receptacle”, and ready to accept contents therein. In other examples, the receptacle may be fully formed without the neck fitment 35 being affixed and/or without the interior coating being applied and/or without the exterior coating being applied and/or without the decoration being applied and/or immediately after one of the drying processes or one of the inspecting and/or evaluating processes. For example, in some cases, the product is provided with the closure part by moulding the closure part during moulding of the product at the first moulding station and/or the second moulding station.

Figure 2 shows a moulding system 101, which in this example is a thermoforming system 101, which may be used to thermoform the self-supporting moulded product 22 removed from the mould 15 discussed with respect to Figure 1. The product 22 may be termed a hollow moulded fibre product precursor, and in this example is a necked receptacle having a main body portion 22a with a central longitudinal axis 22b, a base end portion or base 22c, and an upper end portion comprising a necked portion 22d at an opposite end of the product 22 to the base 22c. The moulding system 100 comprises a mould 103, a suction generator 105, a first suction line 107, a second suction line 109, and a transfer mechanism 111. The mould 103 may, in some examples, be the mould 25 described above with reference to Figure 1.

The mould 103, shown in cross-section in Figure 2, comprises a first part 119 and a second part 121. In other examples, the mould 103 may comprise more than two parts. The first part 119 is hollow and comprises a cavity 123, a surface 125, a port 127, and a heater 129. In this example, the cavity 123 has the shape of half a bottle. The surface 125 defines the cavity 123 and has a concave shape. The surface 125 comprises a plurality of apertures 131. The apertures 131 extend through the surface 125 to allow fluid to flow between an interior of the part 119 and the cavity 123. Figure 2 shows apertures 131 whose sizes are exaggerated for clarity. In practice, each aperture 131 has a diameter of no greater than 90 pm and no less than 10 pm. The apertures 131 are distributed over no less than 80% of the surface 125. The port 127 is located on an opposite side of the first part 119 to the surface 125 and is connected to the first suction lines 107. The port 127 enables fluid to flow between the first suction line 107 and the interior of the first part 119. The heater 129 is operable to heat the first part 119 and thereby heat the cavity 123. The second part 121 is identical to the first part 119 except that the second part 121 is connected to the second suction line 109. The second part 121 is moveable relative to the first part 119 to change the mould 103 between an open configuration and a closed configuration. In this example, the second part 121 is moved by a hydraulic piston. However, in other examples, the second part 121 may be moved by other means, for example, by an operator of the mould system 101. In the open configuration, shown in Figure 2, the two parts 119,121 of the mould 103 are spaced from one another such that there is sufficient space between the two parts 119,121 for a partially formed receptacle 22, such as the self-supporting moulded product 22 described above, to be moved into and out of the cavity 123 of the first part 119.

In the closed configuration (shown in Figure 4e), the parts 119,121 abut one another along a split plane 104, such that movement of the product 22 into and out of the cavity 123 of the first part 119 is inhibited. Additionally, in the closed configuration, a mould cavity is created within the mould that comprises the cavities 123 of the first part 119 and the second part 121. The mould cavity has the shape of a bottle and generally corresponds to the shape of the product 22. When the product 22 is in the mould cavity, a central longitudinal axis 22b of the self-supporting moulded receptacle extends along the split plane 104 and is coaxial with a central longitudinal mould cavity axis.

The suction generator 105 is connected to the suction lines 107,109. The suction generator 105 is operable to generate a suction force 133 (shown in Figures 4c-4e) in the first suction line 107. Due to the cavity 123 of the first part 119 being connected to the first suction line 107 via the apertures 131, the interior of the first part 119 and the port 127, the suction force 133 is applicable to the cavity 123 of the first part 119 via the apertures 131 in the surface 125 of the first part 119. The suction generator 105 is operable to generate the suction force 133 in the second suction line 109 (shown in Figure 4(d)). Thereby, in an analogous manner to the first part 119, the suction force 133 is applicable to the cavity of the second part 121 via the apertures in the surface of the second part 121. In this example, the suction generator 105 is a vacuum pump.

Each of the suction lines 107,109 connects to the suction generator 105 and a respective port 127 of each of the parts 119,121. In some examples, a suction separation tank may be located along each of the suction lines 107,109 between the suction generator 105 and each of the ports 127. The suction separation tank is operable to remove steam from the suction lines 107,109 which may be generated (as will be discussed in more detail below) when a forming operation is applied to the product 22 within the mould 103.

The transfer mechanism 111 is for inserting the product 22 into, and in some examples demoulding the product 22 from, the mould 103. The transfer mechanism 111 comprises a contact portion 113 and an transfer arm 117. The transfer arm 117 in this example is an articulated arm that is movable by actuators (not shown) to move the product 22 between different locations. The transfer arm 117 is connected to the contact portion 113 via a hinge 118, which permits rotation of the contact portion 113 relative to the transfer arm 117 about the hinge 118. In this example, rotation about the hinge 118 is about an axis extending into the page of Figure 2.

Figure 3 shows the contact portion 113 in more detail. The contact portion 113 comprises a contact surface 114 shaped to correspond to an outer wall of the main body portion 22a of the product 22. A plurality of apertures 115 are defined in the contact surface 114. Figure 3 shows apertures 115 whose sizes are exaggerated for clarity. In practice, each aperture 115 has a diameter of no greater than 90 pm and no less than 10 pm. A transfer mechanism port (not shown) is located on an opposite side of the contact portion 113 to the contact surface 114 and is connected to a transfer mechanism suction line 116 housed within the transfer arm 117. The contact portion 113 defines an inner void, and the transfer mechanism port enables fluid flow through the apertures 115, through the void and into the transfer mechanism suction line 116. In use, fluid (air, in this example) is drawn through the apertures 115 by a suction generator 118 at sufficient speed to generate enough force to hold the product 22 against the contact surface 114.

In this example, the transfer mechanism 111 is configured to demould the product 22 from the mould 15 described above before transferring the product 22 to the mould 103. The contact surface 114 is held against, or close to, the product 22 in the mould 15. Suction is then generated along the transfer arm suction line to draw air through the apertures 115, which draws the product 22 against the contact surface 114.

Figures 4a-4e show the thermoforming system 101 at various stages during use of the thermoforming system 101. Figure 4a, shows the thermoforming system 101 before a use, or between uses, of the mould 103. The mould 103 is in the open configuration and the transfer mechanism 111 is positioned with the contact portion 113 held above the mould 103 by the transfer arm 117. Suction is being generated in the transfer mechanism suction line so that a product 22 is held against the contact surface 114. The contact portion 113 is at such a rotational position relative to the transfer arm 117 that a central longitudinal axis 22b of the product 22 is at a first angle Al, in this example of around 10 degrees, from the split plane 104.

In Figure 4b, movement of the transfer arm 117 from the position shown in Figure 4a has caused the contact portion and the product 22 to be lowered between the first and second parts 119, 121 of the mould 103. The transfer arm 117 has also moved the product 22 towards the first part 119 of the mould 103 such that a lower end of the product 22 crosses the split plane 104 and passes into the cavity 23 of the first part 119. A centre of a base 22c of the product 22 abuts a lower edge 120 of the first part 119 at the split plane 104. The central longitudinal axis 22b of the product 22 is still at the first angle Al of around 10 degrees from the split plane 104.

Although shown at the same angle in Figures 4a and 4b, in other examples the contact portion 113 holds the product 22 at a different angle at the position shown in Figure 4a, and rotates about the product 22 relative to the split plane 104 as the product 22 is lowered between the first and second parts 119, 121 of the mould 103. In any event, as the product 22 is moved towards the first part 119 of the mould, the product 22 is held against the contact surface 114 with the central longitudinal axis 22b at a non-zero angle, in this example 10 degrees, from the split plane 104. Accordingly, the lower end of the product 22 crosses the split plane 104 with the product 22 at an angle relative to the mould 103, and thus the split plane 104, that is different to an angle at which the product 22 sits in the mould 103 during moulding by the mould 103.

Although in this example the initial angle of insertion of the product 22 into the first part 119 of the mould 103 is shown as around 10 degrees, in other examples an alternative angle is employed, such as around 5 degrees, around 20 degrees, or any other suitable angle. In Figure 4c, the contact portion 113 is rotated relative to the transfer arm 117 about the hinge 118, as compared to the position shown in Figure 4b. Such rotation of the contact portion 113 causes the central longitudinal axis 22b of the product 22 to move to a second smaller angle A2 from the split plane 104 compared with the first angle Al shown in Figure 4b. In this example the second angle A2 is around 3 degrees from the split plane 104. The product 22 is rotated about the lower edge 120 of the first part 119, which causes part of the necked portion 22d of the product 22 to cross the split plane 104 and pass into the cavity 23 of the first part 119. As, or when, the product 22 is moved to the position shown in Figure 4c, the suction generator 105 (not shown in Figures 4a-4e for clarity) is caused to generate suction in the first suction line 107. This generates a suction force 133 and thus draws the product 22 towards the surface 125 of the first part 119 to the position shown in Figure 4d.

With the transfer mechanism 111 and product 22 at the position shown in Figure 4c, suction along the transfer arm suction line is removed, or in other examples is reduced without being entirely removed. This releases the product 22 from the contact surface 114. The suction force 133 is sufficient to draw the self-supporting moulded receptacle 22 against the surface 125 of the first part 119, so that the central longitudinal axis 22b extends along the split plane 104, as shown in Figure 4d.

In other examples, the transfer mechanism 111 physically moves the product 22 to the position shown in Figure 4d, that is a position in which an angle between the central longitudinal axis 22b and the split plane 104 is substantially zero, before suction along the transfer arm suction line is removed.

In some examples, fluid flow in the transfer arm suction line is reversed after the product 22 reaches the position shown in Figure 4b, or after the product 22 reaches the position shown in Figure 4c. Accordingly, fluid, such as air, is expelled from the apertures 115 on the contact surface 114 of the contact portion 113 to push the product 22 towards the position shown in Figure 4d.

In some examples, the transfer mechanism 111 comprises an actuable lever (not shown) configured to separate the product 22 from the contact surface 114, to move the product 22 towards the position shown in Figure 4c and/or towards the position shown in Figure 4d. For example, the lever may be located on the contact surface 114 and be actuable to selectively protrude from the contact surface 114 to push the product 22 away from the contact surface 114.

The transfer arm 117 is then retracted to remove the contact portion 113 from between the parts 119, 121 of the mould 103 as shown in Figure 4d. The product 22 is held in the first part 119 of the mould 103 by the suction force 133 and the second part 121 of the mould 103 is moved towards the first part 119 until the mould 103 is in the closed configuration, as shown in Figure 4e. With the product 22 in the cavity 23 of the mould 103 and the mould 103 in the closed configuration, the suction generator 105 is caused to additionally generate suction in the second suction line 109. In the position shown in Figure 4d, the central longitudinal axis 22b of the product 22 is substantially coaxial with a central axis of the cavity of the mould 23.

The mould 103 is then used to thermoform the product 22. The first and second parts 119, 121 of the mould 103 are held closed at a pressure of around 19.5 bar during the thermoforming. The transfer mechanism 111 is subsequently used to demould the product 22 from the mould 103. In other examples, a different system to the transfer mechanism 111 is used to demould the product 22 from the mould 103.

Figure 5 shows a method 200 of operating a thermoforming system according to an example, for example the thermoforming system 101 described with reference to Figures 2-4e. The method 200 comprises causing a hollow moulded fibre product transfer mechanism, such as the transfer mechanism 111 described above, to place a hollow moulded fibre product, such as the product 22 described above, in a mould part, such as the first part 119 of the mould 103 described above, at a first angle, such as the first angle Al described above, relative to the split plane of the mould part, as denoted in block 210. In an example, the first angle is 10 degrees from the split plane, such as the split plane 104, as described with reference to Al in Figure 4b.

The method 200 further comprises subsequently causing the hollow moulded fibre product to move to a position orientated at a second angle, such as the second angle A2 described above, relative to the split plane, as denoted in block 220. In an example, the second angle is 3 degrees from the split plane 104, as described with reference to A2 in Figure 4c. In other examples, the second angle is substantially zero degrees from the split plane, such as the split plane 104, as described with reference to Figure 4d.

Figure 6 shows a method 300 of inserting a hollow moulded fibre product into a mould part of a thermoforming mould. The method 300 may be performed by a transfer mechanism, such as the transfer mechanism 111 described above with reference to Figures 2-4e.

The method 300 comprises placing the hollow moulded fibre product in the mould part at a first angle, such as the first angle Al of 10 degrees described above, relative to a split plane of the mould part, as denoted by block 310. In this example, the first angle is at least 5 degrees, but no greater than 20 degrees. In this example, the placing denoted by block 310 of Figure 6 comprises inserting a base end portion of the hollow moulded fibre product into the mould part, as denoted by block 320. However, in other examples, the placing denoted by block 312 of Figure 6 comprises inserting another part of the hollow moulded fibre product into the mould part, such as an upper end, which may be a necked end, of the hollow moulded fibre product.

The method 300 further comprises subsequently causing the hollow moulded fibre product to move in the mould part to a position orientated at a second angle, such as the second angle A2 of 3 degrees described above, relative to the split plane, the second angle smaller than the first angle, as denoted by block 320. In this example, the second angle is no greater than 3 degrees. In some examples, the second angle is substantially zero degrees.

In this example, the subsequently causing the hollow moulded fibre product to move in the mould part to a position orientated at the second angle relative to the split plane denoted by block 320 of Figure 6 comprises causing an upper end portion of the hollow moulded fibre product to enter the mould part. The upper end portion is at an opposite end of the hollow moulded fibre product to the base end portion. In this example, the subsequently causing the hollow moulded fibre product to move in the mould part to a position orientated at a second angle relative to the split plane denoted by block 320 of Figure 6 comprises applying a force to the hollow moulded fibre product to move the hollow moulded fibre product towards the second angle, as denoted by block 324. In an example in which the method is performed by the transfer mechanism 111 described above with reference to Figures 2-4e, the applying a force is by generating the suction force 133 to draw the hollow moulded fibre product 22 towards the first part 119 of the mould 103. In other examples, the force is, additionally or alternatively, applied by physically moving the contact portion 113 with the product 22 held against the contact surface 114, by pushing air out of the apertures 115 on the contact surface 115, and/or by physically separating the product 22 from the contact surface 114, for example by an actuable lever.

In other examples, the applying a force as denoted by block 324 may be omitted. For example, the hollow moulded fibre product may fall under gravity from the first angle towards the position orientated at the second angle following removal of, or reduction in, suction generated in the transfer arm suction line 116.

It will be appreciated that there is provided a control system 112 that is configured to cause the transfer mechanism 111 to perform the relevant method steps outlined in Figures 5 and/or 6.

Figure 7 shows a schematic diagram of a non-transitory computer-readable storage medium 800 according to an example. The non-transitory computer-readable storage medium 800 stores instructions 830 that, if executed by a processor 820 of a control system 810 of a transfer mechanism, causes the transfer mechanism to perform a method according to an example. In some examples, the control system 810 is or comprises the control system 102 as described above, and/or the transfer mechanism is the transfer mechanism 111 of the thermoforming system 101 as described above. The instructions 830 comprise: causing the transfer mechanism to place a hollow moulded fibre product in a mould part at a first angle relative to a split plane of the mould part, and subsequently cause the hollow moulded fibre product to move in the mould part to a position orientated at second angle relative to the split plane, wherein the second angle is smaller than the first angle. In other examples, the instructions 830 comprise instructions to cause the transfer mechanism to perform any other example methods described herein.

It will also be appreciated that there also is provided a receptacle manufacturing line (such as that shown in Figure 1) comprising a thermoforming system for processing a self-supporting hollow moulded product and apparatus for performing at least one additional process on the self-supporting hollow moulded product to provide the receptacle. Similarly, also provided is a method of manufacturing a receptacle, the method comprising operating a thermoforming system to process a self-supporting hollow moulded product, and then performing at least one additional process on the self- supporting hollow moulded product to provide the receptacle. Examples of the “at least one additional process” are described above with reference to Figure 1.

Also provided, as a result of the content of the present application, is use of a receptacle obtained by any of the methods described herein to contain contents. An example such receptacle 900, in the form of a necked receptacle and specifically a bottle, containing contents 910 is shown in Figure 8. The use could be, for example, by a person who puts the contents into the receptacle, by a person who transports the contents, or by a person who wishes to dispose of (for example, to a consumer or end user), offer to dispose of (for example, to a consumer or end user), import, or keep the contents whether for disposal or otherwise. The contents could, for example, be any one or more of the example contents described herein.

Also provided is a method of providing a content-containing receptacle. An example such method 1000 is shown in Figure 9. The method 1000 comprises providing 1010 the receptacle, in the form of a necked receptacle and specifically a bottle, and then providing 1020 the contents in the receptacle. In this example, block 1020 follows block 1010, so that block 1020 comprises putting the contents into the receptacle that has been provided at block 1010. However, in some other examples, blocks 1010 and 1020 are performed concurrently, so that the providing 1010 the receptacle comprises providing the receptacle with the contents already present in the receptacle. The contents could, for example, be any one or more of the example contents described herein. The method 1000 also comprises closing 1030 an opening of the receptacle after block 1020, and applying 1040 a label or indicia to the receptacle after block 1030. In this example, block 1030 involves applying a heat seal to the opening and then screwing a cap or lid onto the receptacle, and block 1040 comprises adhering a label onto the receptacle.

In respective other examples, the order of blocks 1030 and 1040 is reversed, blocks 1030 and 1040 are performed concurrently, block 1030 is omitted, and block 1040 is omitted. In some examples, block 1040 occurs before block 1020, orblock 1040 occurs during block 1020. For example, in some cases, the label or indicia is applied to the receptacle, then the contents are provided in the receptacle, and then the receptacle is closed.

It will be appreciated that the method 1000 could be performed by the same party that manufactures the receptacle, for example so that block 1010 comprises the method discussed above with reference to the manufacturing line shown in Figure 1. Alternatively, the method 1000 could be performed by a different party to that which manufactures the receptacle. In such an alternative, the different party performs block 1010 by way of obtaining the receptacle from the party that manufactures the receptacle (such as by way of the method discussed above with reference to Figure 1) or from an intermediary.

Example embodiments of the present invention have been discussed, with reference to the examples illustrated. However, it will be appreciated that variations and modifications may be made without departing from the scope of the invention as defined by the appended claims.

Claims

CLAIMS:

1. A method of inserting a hollow moulded fibre product into a mould part of a thermoforming mould, the method comprising: placing the hollow moulded fibre product in the mould part at a first angle relative to a split plane of the mould part; and subsequently causing the hollow moulded fibre product to move in the mould part to a position orientated at a second angle relative to the split plane, wherein the second angle is smaller than the first angle.

2. The method of claim 1, wherein the placing the hollow moulded fibre product in the mould part at the first angle relative to the split plane of the mould part comprises inserting a base end portion of the hollow moulded fibre product into the mould part, and the subsequently causing the hollow moulded fibre product to move in the mould part to a position orientated at the second angle relative to the split plane comprises causing an upper end portion of the hollow moulded fibre product to enter the mould part, the upper end portion being at an opposite end of the hollow moulded fibre product to the base end portion.

3. The method of claim 1 or claim 2, wherein the subsequently causing the hollow moulded fibre product to move to the position orientated at the second angle relative to the split plane comprises applying a force to the hollow moulded fibre product to move the hollow moulded fibre product towards the second angle.

4. The method of any of claims 1 to 3, wherein the first angle is at least 5 degrees from the split plane of the mould part.

5. The method of any of claims 1 to 4, wherein the first angle is no greater than 20 degrees from the split plane of the mould part.

6. The method of any of claims 1 to 5, wherein the second angle is no greater than 3 degrees from the split plane of the mould part.

7. The method of claim 6, wherein the second angle is substantially zero degrees from the split plane of the mould part.

8. A hollow moulded fibre product transfer mechanism for inserting a hollow moulded fibre product into a mould part of a thermoforming mould, the hollow moulded fibre product transfer mechanism configured to: partially insert the hollow moulded fibre product into the mould part at a first angle relative to a split plane of the mould part, and subsequently cause the hollow moulded fibre product to move in the mould part to a position orientated at a second angle relative to the split plane to further insert the hollow moulded fibre product into the mould part, wherein the second angle is smaller than the first angle.

9. The hollow moulded fibre product transfer mechanism of claim 8, configured to: partially insert a base end portion of the hollow moulded fibre product into the mould part such that the hollow moulded fibre product is at the first angle, and subsequently cause the hollow moulded fibre product to move in the mould part to a position orientated at the second angle relative to the split plane by partially inserting an upper end portion of the hollow moulded fibre product into the mould part, the upper end portion at an opposite end of the hollow moulded fibre product to the base end portion.

10. The hollow moulded fibre product transfer mechanism of claim 8 or claim 9, configured to apply a force to the hollow moulded fibre product to move the hollow moulded fibre product towards the position orientated at the second angle.

11. The hollow moulded fibre product transfer mechanism of any of claims 8 to 10, comprising: a contact surface for contacting a surface of the hollow moulded fibre product; a suction generator configured to apply a suction force to the surface of the hollow moulded fibre product to retain the hollow moulded fibre product against the contact surface; and an actuation system configured to move the contact surface, with the hollow moulded fibre product retained against the contact surface by the suction generator, relative to the mould part and partially insert the hollow moulded fibre product into the mould part at the first angle.

12. The hollow moulded fibre product transfer mechanism of claim 11, wherein the suction generator is configured to release the surface of the hollow moulded fibre product from the contact surface when the actuation system has partially inserted the hollow moulded fibre product into the thermoforming mould.

13. The hollow moulded fibre product transfer mechanism of claim 11 or claim 12, wherein the transfer mechanism is configured to apply a pushing force to a surface of the hollow moulded fibre product in a direction away from the contact surface to release the surface of the hollow moulded fibre product from the contact surface.

14. The hollow moulded fibre product transfer mechanism of claim 11, wherein the actuation system is configured to subsequently move the contact surface, with the hollow moulded fibre product retained against the contact surface by the suction generator, to move the hollow moulded fibre product towards the position orientated at the second angle.

15. The hollow moulded fibre product transfer mechanism of claim 14, wherein the suction generator is configured to release the surface of the hollow moulded fibre product from the contact surface when the actuation system has moved the hollow moulded fibre product to the position orientated at the second angle.

16. The hollow moulded fibre product transfer mechanism of any of claims 11 to 15, comprising a second actuation system configured to move the hollow moulded fibre product towards the position orientated at the second angle.

17. The hollow moulded fibre product transfer mechanism of any one of claims 8 to 16, configured, before partially inserting the hollow moulded fibre product into the mould part at the first angle relative to the split plane of the mould part, to: remove the hollow moulded fibre product from a first mould, the first mould being for moulding the hollow moulded fibre product before moulding of the hollow moulded fibre product by the thermoforming mould; and rotate the hollow moulded fibre product to the first angle.

18. A thermoforming system for processing a hollow moulded fibre product, the thermoforming system comprising the hollow moulded fibre product transfer mechanism of any of claims 8 to 17 and a thermoforming mould comprising a plurality of mould parts, the transfer mechanism configured to: partially insert the hollow moulded fibre product into one of the mould parts of the thermoforming mould at the first angle relative to a split plane of the mould part, and subsequently cause the hollow moulded fibre product to move to the position orientated at the second angle relative to the split plane to further insert the hollow moulded fibre product into the mould part.

19. A method of operating the thermoforming system of claim 18, the method comprising: causing the hollow moulded fibre product transfer mechanism to place the hollow moulded fibre product in the mould part at the first angle relative to the split plane of the mould part; and subsequently causing the hollow moulded fibre product to move to the position orientated at the second angle relative to the split plane.

20. A control system configured to cause a hollow moulded fibre product transfer mechanism to perform the method of any one of claims 1 to 7, or to cause a thermoforming system to perform the method of claim 19.

21. A non-transitory storage medium storing machine-readable instructions that, when executed by a processor of a control system of a transfer mechanism, cause the transfer mechanism to perform the method of any one of claims 1 to 7, or the method of claim 19.

22. A receptacle manufacturing line comprising the thermoforming system of claim 18 for processing the hollow moulded fibre product, and apparatus for performing at least one additional process on the hollow moulded fibre product to provide the receptacle.

23. A method of manufacturing a receptacle, the method comprising performing the method of any one of claims 1 to 7 to provide a hollow moulded fibre product, thermoforming the hollow moulded fibre product in the thermoforming mould to provide a thermoformed hollow moulded fibre product, and then performing at least one additional process on the thermoformed hollow moulded fibre product to provide the receptacle.

24. A method of providing a content-containing receptacle, the method comprising providing a receptacle obtained by the method of claim 23 and providing contents in the receptacle to provide the content-containing receptacle.

25. Use of a receptacle obtained by the method of claim 23 to contain contents.